Device and method for shaping terminal leads

ABSTRACT

A device for shaping terminal leads is used to bend terminal leads that extend from an electrical component body. The device includes a bearing that is mounted on a shaft. As the shaft is moved in a linear direction relative to the component body, the bearing rolls against the terminal lead to bend the terminal lead toward the component body. Since the bearing does not slide along the terminal lead, damage to the terminal lead is minimized.

TECHNICAL FIELD

[0001] The present invention relates generally to sensors and actuators.

BACKGROUND OF THE INVENTION

[0002] Modern motor vehicles are equipped with numerous control systems, e.g., anti-lock brake systems, ride control systems, traction control systems, and air bag deployment systems, that provide comfort and safety to drivers and passengers of these vehicles. Each of these systems require numerous sensors and actuators that are used to determine relative part-to-part motion and control the interaction of the components within the systems. These sensors and actuators are electrically connected to control modules in order to send and receive signals crucial to the operation of the systems. Thus, each sensor or actuator includes at least one terminal lead which is soldered or otherwise connected to a wire from its respective control module.

[0003] During the manufacture of these sensors and actuators, the terminal leads attached thereto may be bent relative to the sensor body or actuator body before being placed in a housing. Typically, a jaw or rigid tool is used to bend the terminal leads. As recognized by the present invention, the use of a jaw or rigid tool can cause the terminal leads to flake or otherwise chip, resulting in harmful debris. Moreover, the jaw or rigid tool can cause undue stress on the terminal and cause premature failure of the sensor or actuator. The present invention also recognizes that the jaw or rigid tool can cause unwanted wear or scarring on the terminal leads.

[0004] The present invention has recognized the prior art drawbacks, and has provided the below-disclosed solutions to one or more of the prior art deficiencies.

SUMMARY OF THE INVENTION

[0005] The present invention is a method for shaping a terminal lead that extends from an electric component body. Accordingly, the method includes holding the component body stationary and then, moving a bending device relative to the component body and rollably along the terminal lead. As the bending device moves, it causes the terminal lead to bend toward the component body.

[0006] In a preferred embodiment, the terminal lead is allowed to bend until it is flat against the component body. Thereafter, the terminal lead is welded to the terminal body. Preferably, the component body is installed in a holder. In a presently preferred embodiment of the invention, the bending device includes a shaft and a bearing that circumscribes the shaft. The shaft moves in a linear direction relative to the component body and the bearing rotates relative to the component body. Preferably, as the shaft moves linearly with respect to the component body, the bearing rolls along the terminal.

[0007] In another aspect of the present invention, an assembly for shaping a terminal lead that extends from an electrical component body includes the electrical component body, a shaft, and a bearing that circumscribes the shaft. In this aspect of the present invention, the shaft moves relative to the component body such that the bearing rolls along the component body to bend the lead toward the component body.

[0008] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a plan view of the bending device and electrical component prior to the bending process;

[0010]FIG. 2 is a plan view of the bending device and electrical component during the bending process;

[0011]FIG. 3 is a plan view of the bending device and electrical component after the bending process; and

[0012]FIG. 4 is a perspective view of the electrical component installed in a plastic holder.

DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

[0013] Referring initially to FIG. 1, an electrical component, e.g., a sensor or actuator, is shown and generally designated 10. As shown in FIG. 1, the electrical component 10 includes a component body 12 and a first terminal lead 14 extending therefrom. FIG. 1 also shows a bending device, generally designated 16. The bending device 16 includes a solid, generally cylindrical bearing 18 mounted on a shaft 20. As intended by the present invention, the shaft 20 moves to the left and right, as indicated by direction arrow 22. As the shaft 20 moves to the left or right, the bearing 18 is free to rotate on the shaft 20 in either direction, as indicated by direction arrow 24.

[0014] Referring to FIG. 2, as the shaft 20 moves to the right looking down on FIG. 2 and the component body 12 remains stationary, the bearing 18 pushes against the first terminal lead 14 causing it to bend along arc 26, toward the component body 12. As the bearing 18 bends the first terminal lead 14, the bearing 18 rotates clockwise and rolls along the first terminal lead 14. Thus, the bearing 18 does not slide along the first terminal lead 14 and does not damage the first terminal lead 14 as it bends it.

[0015] As the shaft 20 continues to move to the right, looking down on FIG. 3, and the bearing 16 continues to roll along the first terminal lead 14, the first terminal lead 14 is bent flat against the component body 12. Thereafter, the first terminal lead 14 is soldered, or otherwise welded, in place against the component body 12.

[0016] As shown in FIG. 4, this configuration of structure is then installed in a preferably plastic holder 28. FIG. 4 also shows that the component body 12 includes a second terminal lead 30. It can be appreciated that the second terminal lead 30 is bent against the component body 12 in the same manner as the first terminal lead 14. As shown in FIG. 4, the holder 28 includes a first electrical connector 32 and a second electrical connector 34. The terminal leads 14, 30 are soldered or otherwise welded to the electrical connectors 32, 34 to form an electrical component package 36.

[0017] With the configuration of structure described above, it is to be appreciated that the device and method for shaping terminal leads provides a means by which a terminal lead can be bent relative to an electric component with minimal damage to the terminal lead.

[0018] While the particular DEVICE AND METHOD FOR SHAPING TERMINAL LEADS as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it is to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” 

1. A method for shaping at least one terminal lead extending from an electric component body, comprising the acts of: holding the component body stationary; moving a bending device relative to the component body and rollably along the terminal lead, the bending device causing the terminal lead to bend toward the component body.
 2. The method of claim 1, further comprising the act of: allowing the terminal lead to bend until it is flat against the component body.
 3. The method of claim 2, further comprising the act of: welding the terminal lead to the terminal body.
 4. The method of claim 3, further comprising the act of: installing the component body in a holder.
 5. The method of claim 1, wherein the bending device comprises: a shaft; and a bearing circumscribing the shaft.
 6. The method of claim 5, wherein the shaft moves a linear direction relative to the component body and the bearing rotates relative to the component body.
 7. The method of claim 6, wherein as the shaft moves linearly with respect to the component body, the bearing rolls along the terminal.
 8. An assembly for shaping at least one terminal lead extending from an electrical component body, the device comprising: the electrical component body; a shaft; and a bearing circumscribing the shaft, the shaft movable relative to the component body such that the bearing rolls along the component body to bend the lead toward the component body.
 9. The assembly of claim 8, wherein as the shaft moves with respect to the component body, the bearing rolls against the terminal. 